Hsg230 Keeping Electrical Switchgear Safe

Health and Safety
Executive
Keeping electrical switchgear

safe
This is a free-to-download, web-friendly version of HSG230
(First edition, published 2002). This version has been adapted for online use
from HSEs current printed version.
You can buy the book at www.hsebooks.co.uk and most good bookshops.
ISBN 978 0 7176 2359 4
Price 9.50
Failure of electrical switchgear can cause death, serious injury and major
damage. If you own or operate this type of equipment in industrial or
commercial organisations this book is mainly aimed at you. It should help you
to select, use and maintain switchgear safely and reduce the risk of accidents.
Electricity distribution companies or equipment suppliers may also find the
advice useful.
HSE Books
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Crown copyright 2002

First published 2002
ISBN 978 0 7176 2359 4
All rights reserved. No part of this publication may be reproduced, stored in
a retrieval system, or transmitted in any form or by any means (electronic,
mechanical, photocopying, recording or otherwise) without the prior written
permission of the copyright owner.
Applications for reproduction should be made in writing to:
The Office of Public Sector Information, Information Policy Team,
Kew, Richmond, Surrey TW9 4DU or e-mail: licensing@opsi.gov.uk
This guidance is issued by the Health and Safety Executive. Following the guidance
is not compulsory and you are free to take other action. But if you do follow the
guidance you will normally be doing enough to comply with the law. Health and
safety inspectors seek to secure compliance with the law and may refer to this
guidance as illustrating good practice.
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Contents
Introduction 6
Scope 6
Background 6
Legislation 6
Equipment and its location 7
Potential problems with switchgear 8
Lack of knowledge 8
Overstressing 8
Modifications 9
Dependent manual operating mechanisms 9
Lack of maintenance 10
Anti-reflex handles 10
Management of switchgear 11
Records 12
Network diagrams 12
Asset register 12
Maintenance records 13
Operational issues 13
Fault levels and ratings 13
Effect of on-site generation and other large rotating machines 14
Precautions for reducing the risk of switchgear failure and injury 14
Overstressed switchgear 14
Dependent manually operated (DMO) switchgear 15
Modifications 16
Fault clearance 16
Care and maintenance of oil switchgear 17
General advice 17
Inspection 18
Switchgear environment 18
Signs of abnormal condition 18
Switchgear general condition 18
Maintenance 19
Time-based preventive maintenance 19
Condition-based maintenance 19
Reliability-centred maintenance (RCM) 19
Maintenance procedures 19
Frequency of maintenance 20
Oil circuit-breakers subject to special duty 21
Insulating oil 21
Cleaning and inspection of oil-filled chambers 22
Tank cleaning techniques 23
Post-fault maintenance of oil circuit-breakers 23
Keeping electrical switchgear safe
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Care and maintenance of non-oil switchgear 24
General advice 24
Inspection 24
Maintenance 25
Maintenance procedures 25
Sulphur hexafluoride switchgear 25
Vacuum switchgear 26
Air-break switchgear 26
Frequency of maintenance 27
Sulphur hexafluoride gas handling and safety precautions 27
Release of sulphur hexafluoride 28
Hazards 28
Sampling 29
Topping up 29
Care and maintenance of ancillary equipment 30
Test probes 30
Earthing equipment 30
Testing 31
Tests to be undertaken during commissioning 31
Tests to be undertaken during and following maintenance 31
Diagnostic testing 31
Assessment of aged switchgear 32
Assessment process overview 32
Phase 1 Initial considerations 33
Phase 2 Condition assessment procedures 34
Phase 3 Information assessment 34
Phase 4 Review and decision 35
Condition monitoring 35
Available techniques 35
Partial discharge detection 35
Thermographic surveys 36
Mechanism timing tests 36
Strategies for application 36
Protection 37
Protection relay schemes 37
Fuse protection 37
Batteries and chargers 38
Selection of new, replacement or refurbished switchgear 39
General advice 39
Ratings 39
Replacement installations 40
Refurbished/retrofitted switchgear 40
Refurbishment of switchgear 40
Retrofit circuit-breakers for withdrawable switchgear 40
Second-hand equipment 41
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Measures to limit fires 41
Compartmentation 41
Control and extinction 41
Prevention 42
Detection 42
Safety issues 42
Training 43
General advice 43
Operational safety documents 43
Inspection and maintenance 44
Disposal issues 44
Insulating oil 44
Capacitors 44
Sulphur hexafluoride switchgear 45
Appendices 46
A Technical definitions 46
B Further reading 48
C Examples of switchgear configurations 51
D Other sources of information 59
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Introduction
1 This book is aimed primarily at owners and operators of electrical switchgear

in industrial or commercial organisations. Electricity distribution companies or
equipment suppliers may also find the advice useful. It should help managers,
engineers and other relevant personnel understand their responsibilities and duties
in the selection, use, care and maintenance of high-voltage and low-voltage
switchgear.
2 In some circumstances the guidance may not be directly applicable and for
interpretation any queries should be directed to the appropriate enforcing authority.
Definitions of some of the key terms used in the book are provided in Appendix A.
Scope
3 This book provides guidance on the selection, use, care and maintenance of
three-phase electrical switchgear with voltage ratings from 400 V alternating current
(ac) up to and including 33 kV ac. It deals with circuit-breakers, switches, switch
fuses, isolators and high-voltage (HV) contactors. The types covered embrace
switchgear using oil, air, sulphur hexafluoride (SF6) or vacuum as the interrupting
medium.
4 The guidance does not address direct current (dc) switchgear, switchgear used
on single-phase ac traction systems of any voltage, low-voltage moulded case
circuit-breakers, or low-voltage contactors and miniature circuit-breakers.
Background
5 In general, switchgear has a proven record of reliability and performance.
Failures are rare but where they occur the results may be catastrophic. Tanks may
rupture and, in the case of oil-filled switchgear, can result in the ejection of burning
oil and gas clouds, causing death or serious injury and major damage to plant and
buildings in the vicinity of the failed equipment.
6 Modern switchgear using sulphur hexafluoride gas or vacuum as the insulating
medium has removed the hazard of burning oil but inevitably has introduced other
risks that need to be managed. Accident experience has shown that failure usually
occurs at, or shortly after, operation of the equipment. So the way switchgear is
operated, its condition and the circumstances existing in the system at the time of
operation to a large extent determine whether the equipment will function safely.
7 Switchgear of all types and ratings has been manufactured in accordance with
British and international standards for over 60 years. As with most equipment,
current specifications bear little resemblance to those of earlier years and the
previous specifications have been shown, by subsequent experience and by
technical developments, to be deficient. Examples of differing requirements
between earlier and current standards are those relating to operating mechanisms
and fault test sequences.
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Legislation
8 The Health and Safety at Work etc Act 1974 (HSW Act), the Management of
Health and Safety at Work Regulations 1999 (Management Regulations) and the
Electricity at Work Regulations 1989 (EAW Regulations) apply (see Appendix B
Further reading).
9 The HSW Act contains requirements to the effect that anyone employing
people should ensure their safety so far as is reasonably practicable.
10 The Management Regulations require an employer (or self-employed person)
to make an assessment of risks to employees or others, taking specialist
advice where necessary. The level of detail in the assessment should be broadly
proportionate to the risk, which means it needs to be fairly detailed in the case of
switchgear as the risk is one of serious injury or even death.
11 The EAW Regulations require electrical equipment for use at work to be
constructed, maintained and operated in such a way as to prevent danger so far as
is reasonably practicable.
12 Equipment should not to be used where its strength and capability may be
exceeded and it should be protected from excess current. This is discussed in
paragraphs 22 and 23 (see also EAW Regulations, regulation 5).
Equipment and its location
13 In any premises that require a high-voltage supply, that incoming supply often
passes through switchgear to control distribution of electricity within the site.
Switchgear varies in size, age and appearance. Typical examples are shown in
Appendix C. It is important to recognise that the different categories of switchgear,
ie switches, isolators, switch fuses, HV contactors and circuit-breakers, have a
different switching capability and you need to be familiar with the switchgear types
on the site and their purpose.
14 Switchgear is generally located in substations and/or switchrooms, ie areas
that are separated from the day-to-day activity of the premises and which, in
many instances, are visited on a very infrequent basis. Such rooms are generally
locked and access is usually restricted to authorised persons. Periodic inspection
of switchrooms is considered good practice to ensure that deterioration is
not occurring to either the switchgear or the environment. For example, it is
unacceptable for any building damage to cause water or debris build-up on
equipment that is for indoor use. Procedures should be in place to detect and
rectify such faults as quickly as possible.
15 In some premises, low-voltage switchgear will be located in work activity
areas. There will also be cases where high-voltage switchgear and motor starters
are found adjacent to the machinery that they control. It is important that the
equipment is in good condition. Operatives in the area should be made aware of
this and procedures put in place for them to report incidents and/or any damage
that occurs.
16 Occasionally switchgear is located outdoors. This can lead to even fewer
visits than to switchgear located in switchrooms and again a practice of periodic
inspection is necessary, along with procedures to deal with any deterioration that is
found.
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17 Much of the equipment still in service is some 25 years old or more. Equipment
that is 35 or more years old is usually of particularly robust construction. As a
result, it is often assumed (incorrectly) that the equipment has an unlimited life in
service. Much of the older equipment has a limited operation capability and these
limitations are not always understood by operating staff. An example of this is a
situation where a defined delay before operation is necessary after a fault clearance
to allow time for the arc extinction processes to recover.
Potential problems with

switchgear
18 This section highlights a number of potential problems that may be
encountered with switchgear. These are particularly relevant to oil-filled electrical
switchgear that is more than 25 years old but may well be valid for more modern
switchgear, depending on the circumstances of a specific user or site. The following
sub-sections provide guidance on dealing with the relevant issues.
Lack of knowledge
19 Switchgear should be operated by trained staff, who are often known as
authorised persons. In the past these were generally works electrical engineers
and senior supervisors but due to changing employment patterns this is no
longer the case. Some users may not have any authorised persons on their staff
and may have chosen to contract out all operational work and maintenance of
their switchgear. As a result, there may be no one within the organisation who
understands the equipment, its safe operation or the need for maintenance. This
should be treated as unacceptable and steps should be taken to remedy the
situation.
20 Staff responsible for care, operation and maintenance of switchgear should
receive training (or refresher courses) relevant to the duties that are required of
them. This is particularly relevant to staff called upon to operate switchgear and
such staff should have competency at the authorised person level. Even where
all operational and maintenance work is contracted out, it is preferable that there
is sufficient technical knowledge within the company to audit the practices of
the contractors and to handle abnormal (including emergency) situations that will
inevitably arise on the premises. If this is not the case, this role should be given to
an independent organisation.
21 A number of organisations (eg electricity distribution companies or specialist
training organisations) provide training courses to the varying levels of competency
that may be required.
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Overstressing
22 Switchgear is described as being overstressed when the potential fault
energy of the electrical system (eg from a short-circuit) at the switchgear location
exceeds the fault energy rating of the switchgear. When it is operated under fault
conditions it is unable to cope with the resulting electrical and thermal stress that
can sometimes lead to catastrophic failure, ie total destruction of the switchgear.
Such failures are accompanied by arc discharge products, burning gas clouds and
oil mist (if oil switchgear). These envelop anyone near the switchgear, resulting in
serious burn injuries and often death.
23 While the original installation design may have been adequate, modifications
and extensions to the network that feeds the switchgear, or of the network
controlled by it, can lead to situations where the switchgear is overstressed. An
example is where the infeed capacity has been increased. Also some configurations
of the network (eg by paralleling of transformers onto the switchgear busbars) can
lead to an overstressing situation. Such situations should be documented and
clear operating instructions provided to prevent such a configuration being created.
They can result from a response to an abnormal operational situation whereby an
incorrect network configuration is inadvertently set up.
Modifications
24 Over the years, manufacturers have issued details of modifications to existing
equipment that should be carried out on switchgear to improve its safety. However,
the procedures for circulating such information are not perfect and in many cases
users are unaware of the need to carry out these modifications. As a result, the
equipment may be incapable of performing satisfactorily. It would be wise to carry
out an audit, if one has not already been undertaken, of the switchgear for which
the user is responsible and liaise with the manufacturers (or other appropriate
expert) to identify any outstanding modifications.
25 It is also good practice to catalogue any circulars or instructions that are
received relating to modifications and make them readily available to all staff whose
duties involve the operation and maintenance of switchgear.
Dependent manual operating mechanisms

26 The operating mechanisms of most switchgear, ie independent manual,
dependent power, independent power and stored energy (see Appendix A for
definitions), do not result in any particular risks. However, this is not the case where
switchgear is of the dependent manually operated (DMO) type. DMO mechanisms
were fitted to both high- and low-voltage switchgear but these types of operating
mechanism are no longer made.
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27 With DMO switchgear, the operator closes or opens the switchgear solely
by manual effort. Therefore movement of the contacts is totally dependent upon
the speed and actions of the person operating the levers/handles. Any hesitancy
on the part of the operator is likely to lead to a serious and potentially fatal failure
of the switchgear, eg operators may not realise that they have failed to close the
circuit-breaker completely and release the operating lever/handle, thus drawing
an arc within the oil tank which can result in catastrophic failure. It is essential
that these levers/handles are operated in a decisive and positive manner without
any hesitation and as rapidly as possible, particularly over the latter portion of the
closing operation. In addition, should a lever/handle be closed onto a system fault,
the force needed is significantly greater than when closed onto normal system load
current. In some cases it may be physically impossible to close (or open) the device
under fault conditions, again this may result in failure. See paragraphs 54-58 for
guidance on actions to take in these situations.
Lack of maintenance
28 This is usually the result of oversight, lack of knowledge of the equipment, or
pressures to avoid plant shutdowns. Whatever the cause, it will lead to a situation
where switchgear has been neglected (this is particularly true of low-voltage
devices). The result is that routine servicing such as oil changing, lubrication,
contact refurbishment, and verification of contact engagement may not have
been carried out for many years and deterioration due to corrosion may also have
occurred. In some cases the expertise in maintenance techniques and for handling
insulating oil is lacking.
29 Where oil-filled switchgear has been neglected, it is difficult to assess the
actual fault capability of the switchgear in the state in which it is found. An audit of
maintenance records should be carried out to establish whether or not there is a
problem and, if necessary, a detailed condition assessment should be made.
Anti-reflex handles
30 At one time, a common cause of accidents/incidents with high-voltage
switches was when an operator carried out an incorrect operation when moving
the operating handle (eg switching from OFF to EARTH instead of from OFF to ON)
and then immediately attempted to reverse that incorrect operation. As oil switches
are not rated for the interruption of fault current, any attempt to open them when
fault current is flowing is likely to lead to disruptive failure, with the possibility of the
operator(s) being killed.
31 To address this problem, many manufacturers have produced anti-reflex
operating handles for their equipment. These handles are one-way operating
devices and have to be removed and relocated before carrying out a further
operation, thus imposing a time delay between operations. This built-in time delay
means that when the incorrect operation is reversed, no fault current is flowing (as
the circuit protection will have operated to interrupt the current flow), and there is
no likely failure of the switch. The built-in time delay is also important when closing
from OFF to ON onto a known fault.
32 A review of the oil switches and oil switch fuses should be undertaken to
determine whether an anti-reflex facility exists. Where no such facility exists, action
should be taken to retrofit an appropriate modification.
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Management of switchgear
33 It is the duty of all users of switchgear to provide management systems that will
ensure safe operation and minimise the risk of injury. Such management systems
should include the following:
(a) policies and procedures covering the installation, commissioning, operation,
maintenance and removal of the equipment;
(b) an appropriate system of records;
(c) definition of responsibilities and training requirements;
(d) auditing of the effectiveness of procedures.
34 An important pre-requisite is to identify all switchgear in service and to
ensure that up-to-date records of network diagrams and configurations (including
prospective fault level values at every relevant point on the system) are available.
From this basic information, any potential risks, eg overstressing or dependent
manual operation, should be assessed so that any necessary remedial action can
be identified to ensure that the equipment and systems are being operated safely,
and that work is put in hand to eliminate or reduce the risks. The basic records for
an LV installation may also contain electrical installation certificates and periodic
inspection reports. Further information is in BS 7671 (see Appendix B Further
reading).
35 Sufficient technical expertise may not be available in-house to carry out a risk
assessment and decide on the appropriate precautions. In such cases switchgear
users should take advice from suitably competent organisations, including:
(a) electricity distribution companies;
(b) switchgear manufacturers;
(c) switchgear maintenance companies with particular expertise in older types of
switchgear;
(d) consulting organisations specialising in switchgear.
36 The British Electrotechnical and Allied Manufacturers Association (BEAMA)
can provide up-to-date details of manufacturers and the Institution of Electrical
Engineers (Presidents list of experts) may also be able to provide help and
guidance as to other sources of information and expertise (see Appendix D for their
addresses).
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Records
37 All switchgear users should have a record of their switchgear available. Where
there are doubts about the accuracy or validity of records then a new inventory
should be prepared as a matter of urgency. The basic records that are suggested
are discussed below.
Network diagrams
38 The diagram is a schematic representation of the network and it is ideal to
display the interconnection of the plant items, including the switchgear. This allows
the normal and any alternative arrangements of the network to be displayed
in a way that is readily understood, bearing in mind that there may be several
switchrooms or substations on any one site. In addition, the diagrams can be
annotated with the status of the switchgear in a particular network arrangement to
avoid any confusion, particularly where overstressing may be an issue.
Asset register
39 An asset register forms the basis of management information providing both
basic identification information (location, type etc) and performance/maintenance
records. Although some items may not be scheduled to receive any routine
maintenance, all items that are likely to receive some kind of attention during their
life should be included. A hierarchical structure is essential to ensure a logical
approach to establishing information for asset management purposes. It is possible
to develop complex hierarchies, but most asset owners find that a two- or threelevel hierarchy is sufficient. A typical structure might involve:
Level 1: Location/cost centre/process or production grouping
Equipment associated with an activity, eg production department.
Level 2: Unit
Collection of plant items that are interdependent and adjacent to each other in
Level 1.
Level 3: Item
Distinct item of plant within the unit, usually the smallest discrete piece of
equipment from an operational point of view, eg item of switchgear, tripping battery
etc.
40 Use of a hierarchical structure allows the straightforward development of an
asset numbering system, eg an item can be coded as a combination of the cost
centre code, the unit code and its own code to provide a unique code.
41 Along with the structure, the level of information to be recorded against
each item needs to be decided. Collecting plant data can be a time-consuming
and costly exercise, particularly basic data that does not directly contribute to
improvements in performance and safety. Care should be taken not to collect too
much basic data and typical information that is required for an item of switchgear at
each location includes:
(a)
(b)
(c)
(d)
location (may already be defined by the structure);

manufacturer and type reference;
serial number and year of manufacture;
date of installation;
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(e)
(f)
(g)
(h)
voltage rating;
current rating;
fault rating and whether it is a certified or assessed and assigned rating;
type of operating mechanism (dependent manual, independent manual,
dependent power, independent power and stored energy);
(i) details of any modifications, eg fitted anti-reflex handles;
(j) if the equipment is an oil circuit-breaker, whether it is plain break equipment
(ie equipment without arc control devices) or not;
(k) type of electrical protection fitted and details of the settings.
Maintenance records
42 A minimum requirement would be to record:
(a) the date of the last maintenance/oil change (where applicable);
(b) in the case of a circuit-breaker, the number of fault operations since it was last
maintained (if known).
43 This provides a record that maintenance schedules are being adhered to and
also provides planning for the next maintenance. As will be seen in later sections,
some measurements are taken during the maintenance and it is valuable to record
such data in order to determine trends in performance and what problems are
emerging. Such records should be retained as a history and the information should
not overwrite the previous record.
Operational issues
Fault level and ratings

44 For each item of switchgear identified in the site inventory (in particular the
DMO switchgear) you need to take the following steps:
(a) Identify the British Standards or other standards relevant to the individual
switchgear.
(b) Calculate fault energy levels at the output terminals of each item of switchgear.
In some cases it will be necessary to include the fault energy contribution from
rotating plant such as large induction motors, synchronous motors and
generators. The electricity supply company is required to provide, on request,
the maximum short-circuit current at the incoming supply terminals (Electricity
Supply Regulations 1988 regulation 32 or Electricity Safety, Reliability and
Continuity Regulations 2002, regulation 27).
(c) Determine the switchgear rating. Where switchgear is in use that was designed
to obsolete British Standards (see Appendix B), reassessment of the rating by
manufacturers or specialists may be necessary.
(d) Compare the fault energy levels calculated in (a) with the certified or assigned
switchgear fault energy rating determined in (c) to establish whether the
equipment is overstressed.
45 It is recommended that the procedures are applied to both high-voltage (ie 3.3
kV, 6.6 kV, 11 kV, 22 kV and 33 kV) systems and low-voltage (230/415 V) systems
as separate exercises. It may be easier to deal with each individual system at each
voltage separately as the individual system may have very different problems.
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46 Other than for the simplest of system configurations, the calculation of fault
levels is a specialist topic requiring support from people experienced in undertaking
and interpreting such calculations.
Effect of on-site generation and other large rotating machines

47 On-site generating plant and other large rotating machines have an impact
on the operational duty of switchgear, especially in terms of fault current handling,
connection of the generators and synchronous motor drives to the network and on
the protection requirements. The following actions need to be taken:
(a) Check that the fault energy levels at the circuit-breaker(s) controlling the
generators and other large rotating machines are within the capability of the
circuit-breaker, paying particular attention to older switchgear. If this is not
the case, then treat the circuit-breaker as overstressed. (The review of
fault levels discussed in the previous section should have included the on-site
generation.)
(b) Provide measurement equipment to ensure that generator or synchronous
motors are synchronised before closing the controlling circuit-breaker(s),
since attempting to close a circuit-breaker or switch onto networks that are not
synchronised can lead to overstressing.
(c) Estimate the effects on the transient recovery voltage across the controlling
circuit-breaker(s) when opening on a fault being fed by the generator and other
large rotating machines. If this exceeds the rating of the circuit-breaker(s), then
treat the circuit-breakers as overstressed. A problem that may arise with older
switchgear is relating the original test requirements for establishing rating
against the conditions on-site. In these cases expert advice should be sought.
(d) Confirm whether the protection settings in use are appropriate for the situations
when the generation is operating and when it is not operating. For guidance
refer to Electricity Association Engineering Recommendations G59/1, 1991 and
G75, 1996.
Precautions for reducing the risk of switchgear failure and injury

48 The need for precautions to be taken and how quickly they should be
implemented will depend on whether the equipment is overstressed, whether it has
been modified in accordance with manufacturers instructions, the type of operating
mechanism, the maintenance condition etc.
Overstressed switchgear
49 Where the switchgear fault energy rating is less than the potential fault energy
levels, the following actions should be taken immediately, regardless of the type of
operating mechanism:
(a) Prohibit all live operation and disable automatic tripping of the switchgear. This
action will necessitate readjustment of electrical protection further back towards
the source of supply so that the electrical protection at the switchgear can be
made non-operative. The readjustment is needed to ensure adequate levels of
electrical protection for the system.
(b) Prevent people gaining access to the switchgear while it is live.
(c) The switchgear should be maintained in accordance with manufacturers
advice by trained personnel. Particular attention should be paid to insulating oil,
solid insulation, contact assemblies, operating mechanisms, seals and gaskets,
as applicable.
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(d) Reduce the fault energy levels, if possible. In some cases changing system
operating conditions will achieve this, for example operating transformers as
single feeders to switchboards and not in parallel with other transformers.
These changes should be made as soon as possible to reduce the fault energy
level to as low as practicable.
(e) Longer-term measures that can be taken to reduce fault energy levels include
fitting reactors or network reconfiguration. These measures may be used to
reduce fault energy levels to values less than the fault energy ratings of
switchgear. Such actions are normally only a solution for high-voltage
installations. It should be noted these measures will not overcome the problems
associated with switchgear that has no fault energy rating.
50 Where the actions (d) and (e) above reduce the fault energy levels below
the rating of the switchgear, then electrical protection and live operation can be
restored, after necessary measures (eg interlocks) have been provided to prevent
the rating being exceeded at any time.
51 If the actions (d) and (e) in paragraph 49 do not reduce the fault energy levels
below the ratings of the switchgear, and it is sited in open workshop areas, the
provision of blast protection should be considered. This may take the form of
suitable walls or enclosures, the purpose of which is to contain any failure of the
switchgear while it is energised. However, this is a complex matter and it is often
more practicable to make the switchgear dead and provide alternative electrical
supplies.
52 Where high-voltage and low-voltage switchgear share the same switchroom
and only one set of switchgear is overstressed, it will be necessary to either:
(a) keep personnel out until the overstressed switchgear is made dead; or
(b) where space permits, erect a suitable blast wall around that switchgear, thus
permitting personnel access to the other switchgear.
53 In addition to these immediate actions, arrangements should be made to
replace the overstressed switchgear as soon as possible.
Dependent manually operated (DMO) switchgear
54 Dependent manually operated (DMO) mechanisms are generally only found on
older types of oil and air circuit-breakers.
55 All operation and maintenance of DMO switchgear should be restricted to those
personnel trained in the operation of the switchgear concerned. They should also
be aware of the dangers of operating the equipment incorrectly, the construction of
the switchgear and the manufacturers maintenance requirements. The personnel
will need to be familiar with the safe system of work outlined in paragraph 56. It
is essential that the actions listed to allow continued use of DMO switchgear be
treated as short-term measures only.
56 Where the switchgear is not overstressed (ie ratings are greater than the actual
fault energy levels), the following precautions are needed to reduce the risks that
result from the fact that it has dependent manual operation:
(a) All DMO switchgear should be maintained in accordance with the
manufacturers advice. This should include, where applicable, the checking
of seals and gaskets, which should be properly installed and in good condition.
An annual maintenance schedule for this equipment should be prepared and
be implemented.
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(b) Power closing mechanisms should be fitted as a matter of urgency to all high
voltage DMO switchgear (ie 3.3 kV and above). However, this should only be
carried out in accordance with the manufacturers advice. It may not be
possible to obtain the necessary guidance and advice where the original
manufacturer no longer exists and there are no agents. In these cases it is
not advisable to fit power closing mechanisms.
(c) A phased replacement programme should be prepared and implemented for all
DMO switchgear manufactured prior to 1960 and for those high-voltage
systems manufactured and installed after 1960 that cannot be fitted with
power closing mechanisms. In some cases it is possible to obtain replacement
circuit-breakers of modern design (often called cassettes), which can be used
to replace old high- and low-voltage units and can use the existing switchgear
busbar housings and support arrangements. This approach can mitigate the
cost of replacement. Advice should be sought from the manufacturer regarding
this approach see also the section on Selection of new, replacement or
refurbished switchgear (paragraphs 163-175).
(d) When DMO switchgear is to be closed, the preferred method of operation is as
follows (in order to achieve this preferred method of operation it may be
necessary to change system running conditions and adjust the electrical
protection accordingly):
make the system dead upstream using a suitably rated independent
operated switch or circuit-breaker;
check, where practicable, the system beyond the DMO switchgear to
ensure that it is fault-free. This will mean applying various electrical
tests to the system;
if the system is healthy, close the DMO switchgear to ON; and
energise the system from the remote point, ensuring that no personnel are
in the vicinity of the DMO switchgear.
The following can, however, be operated with the system live:
bus-section and bus-coupler circuit-breakers on a fully energised system

(ie live both sides); and
circuit-breakers controlling circuits that have been tested immediately
before closure.
(e) Where the DMO switchgear has recently been operated for the purpose of
routine isolation, it may be reclosed manually, providing the electrical circuit it
feeds has not been disturbed.
57 Where work has been undertaken on the electrical system normally made live
by DMO switchgear, the circuit should be tested comprehensively prior to operation
of the switchgear.
58 Where DMO switchgear is also overstressed the precautions in paragraph 49(a)
and (b) are particularly important.
Modifications
59 Where possible, details of any modifications recommended by the switchgear
manufacturer to improve safety should be identified and implemented and suitable
records kept.
Fault clearance
60 If a circuit-breaker shows any signs of abnormal condition (see paragraph 68)
following a fault clearance operation, it needs to be examined and assessed before
a decision is made to reclose it. The circuit-breaker may need to be maintained
before being reclosed. On some designs of oil circuit-breakers it is normal for small
quantities of oil to be ejected via the tank venting arrangement.
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Care and maintenance of oil

switchgear
General advice
61 Examples of typical oil switchgear arrangements are shown in Appendices C1,
C2, C4, C5 and C6. The main failure modes for oil switchgear, together with their
implications, are listed below.
(a) Faults within oil compartments
These are invariably catastrophic with explosion/fire and often involve personal
injury or fatality and serious damage to the building.
(b) Failure of oil circuit-breaker to trip (mechanism and protection faults)
This usually results in an extended disconnection time due to upstream
circuit-breaker tripping.
(c) Solid insulation faults (external to oil compartments)
These can cause extensive damage to equipment, injury to people and damage
to the building.
62 A major concern is the risk of catastrophic failure resulting from failures within
the oil compartment and these can result from:
(a)
(b)
(c)
(d)
(e)
contaminated insulating oil;

poor maintenance of arc interruption system (contacts and arc control devices);
breakdown of solid insulation;
breaking fault current above rated capability (in the case of a circuit-breaker);
internal component failure.
63 Various actions can be taken to minimise these risks of catastrophic failure and
these are set out below, together with the problem areas they address:
(a) Inspection (non-intrusive)
An external inspection will address obvious signs of abnormal condition that are
detectable by sight, smell and sound.
(b) Maintenance (intrusive)
Maintenance under outage conditions will address problems due to mechanism
defects, insulating oil contamination and deterioration, erosion of contacts and
arc control devices.
(c) Condition monitoring/assessment by partial discharge techniques
These techniques can be used to detect and locate deterioration of solid insulation.
(d) Refurbishment/replacement
This approach can be taken to address problems caused by inadequate rating,
inadequate operating mechanism or arc interruption system, or deteriorated or
defective insulation.
64 The sections below look at the inspection and maintenance actions in detail.
There is information on condition monitoring and assessment techniques in
paragraphs 146-152 and on refurbishment and replacement options in paragraphs
163-175.
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Inspection
65 A regular substation inspection is recommended. At the time of the inspection
any remedial work should be prioritised, so that it is carried out:
(a) immediately (this should always be the case when security of the substation
enclosure has been interfered with);
(b) at the earliest possible opportunity; or
(c) at the next scheduled maintenance.
66 An inspection schedule would be expected to include the following items.
Switchgear environment
67 An inspection sequence for the switchgear environment should include the
following aspects:
(a) switchroom access and surrounds (including fence and external walls, if
outdoors);
(b) signs of trespass and/or interference;
(c) presence and legibility of warning notices;
(d) switchroom internal fabric;
(e) firefighting equipment;
(f) general housekeeping;
(g) signs of water ingress/dampness in switchroom.
Signs of abnormal condition
68 A check for any abnormal conditions should be carried out immediately on
entering the substation and if any danger is suspected then the inspection should
be aborted. Typical warning signs are:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
high temperature in switchroom;

presence of smoke;
smell of hot substances (oil, compound etc);
audible discharges or arcing;
smell of ozone;
signs of leaked oil in vicinity of oil circuit-breaker tank;
signs of fresh compound leaks;
distortion and evidence of sooting on enclosures.
Switchgear general condition

69 The external visual inspection of the switchgear should include the following
items:
(a) general condition of exposed busbars and air break switches (where present);
(b) general condition of the switchgear (rust, oil leaks, oil level gauge etc);
(c) compound leaks from cable boxes, busbar chambers, band joints and end
caps;
(d) ammeters, voltmeters, operation indicators, protection equipment;
(e) labelling, padlocks and key exchange interlocks.
70 In addition to the visual inspections above, the use of limited and non-intrusive
diagnostic screening should be considered for inclusion in an inspection schedule.
The information provided allows users to have confidence in the continuing
safety and reliability of the switchgear until the next maintenance by the detection
of incipient faults before they happen. Details of the techniques that can be
considered are provided in the Condition monitoring section (paragraphs 146152).
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71 A similar external inspection should be carried out on associated equipment,

such as batteries and chargers, control panels and other ancillary equipment.
Maintenance
72 Detailed guidance on the maintenance of electrical switchgear can be found in
BS 6423: 1983 and BS 6626: 1985 (see Appendix B Further reading).
Time-based preventive maintenance
73 Oil-filled switchgear was designed and introduced at a time when the
predominant maintenance philosophy consisted mainly of equipment overhauls at
fixed intervals. Time-based maintenance has been and continues to be applied to
such switchgear. Manufacturers recommendations are available to determine the
maintenance programme and advice can be sought from specialist organisations.
74 Rigorous application of such schedules has provided high levels of reliability,
whereas neglecting maintenance can lead to a switchgear condition where its
ability to perform all its duties safely and satisfactorily is not easy to ascertain. So it
is essential that oil-filled switchgear is properly maintained and the application of a
correctly implemented time-based maintenance programme is a well-proven route.
Condition-based maintenance
75 In recent years attention has focused on condition-based maintenance
where maintenance is dictated by need as revealed by inspections and condition
monitoring techniques or predictive maintenance methods. Some users have
moved to this approach but only after careful assessment of the parameters to be
monitored, techniques for acquiring the condition data and, most importantly, an
understanding of the degradation mechanisms affecting the switchgear and the
criteria on which the decisions to take action are based.
76 When considering moving to a condition-based maintenance approach, the
options available need to be carefully assessed. This should be done preferably
with the assistance of organisations with experience in this area, since the
performance of switchgear is influenced by the electrical and environmental
conditions under which it operates. Simply applying techniques and criteria from
another industry section may not be appropriate.
Reliability-centred maintenance (RCM)
77 RCM can assist in the process of determining the maintenance policy because
it analyses maintenance tasks in a structured way to determine the maintenance
requirements of any item of equipment in its operating context. It does so by taking
account of plant usage and condition, the causes and consequences of failure, and
the required performance standards of the organisation. See Appendix B Further
reading for details of publications which provide more background information on
RCM.
Maintenance procedures
78 Whatever the approach used to determine when maintenance is required, it
is important that the intrusive maintenance work is undertaken in a structured
manner in accordance with a documented procedure/checklist.
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79 Maintenance of oil-filled switchgear should comprise a thorough internal

examination, paying particular attention to the following items, where they apply:
(a) the inspection items listed in paragraph 69;
(b) examination and cleaning of the tank interior, internal mechanism, contacts, arc
control devices, bushings, phase barriers and tank lining;
(c) dressing, refurbishing or replacing main/arcing contacts (including contact
alignment check using oil circuit-breaker slow-close facility);
(d) cleaning of arc control devices or replacement if burnt or worn beyond
acceptable tolerances (cross-jet pots, turbulators etc);
(e) replacement of insulating oil with new, reclaimed or reconditioned oil;
(f) lubrication of operating mechanism and adjustment where required;
(g) replacement of seals and gaskets, clearing vents and checking indicator
windows;
(h) examination of primary isolating contacts for damage, burning,
corrosion - cleaning and refurbishing (as necessary);
(i) checking and lubrication of the oil circuit-breaker isolating mechanism;
(j) checking correct function of position indicators and interlocks;
(k) checking shutter operating mechanisms (as appropriate);
(l) examining inside of cable termination chambers and current transformer
chambers (as appropriate);
(m) examining and checking voltage transformer (as required);
(n) secondary injection testing on circuit-breaker protection system (or, if this is not
scheduled, carry out manual trip-test);
(o) on fuse switches/switch fuses, trip-testing with an appropriate fuse trip-testing
device;
(p) examination of secondary contacts, wiring and auxiliary switches;
(q) checking the truck goes fully into position and switchgear is level as appropriate
when putting back into service.
80 During the maintenance of oil switches, fuse switches and ring main units,
the tank cover should be removed for the minimum time necessary and replaced
immediately after the required work is completed. This will ensure that the risk of
contamination of the tank interior by moisture, airborne particulates, dust, insects
and vegetation (if outdoors) is minimised.
Frequency of maintenance
81 Switchgear should be maintained at a frequency appropriate to the equipment.
The manufacturer, or others, may be able to give advice on this but difficulties
exist in defining the frequency. These are affected by operating policies, types
of switchgear and the reliability requirements. An industrial user whose activities
depend on the reliability of power supply may institute more frequent maintenance
as a means of guarding against power failures than (say) a distribution company
where the duplication built into the network allowing alternative supplies means that
a higher risk of malfunction may be acceptable.
82 Overstressed and/or DMO switchgear needs special attention. If any such
switchgear has not been maintained within the past three years, then maintenance
should be carried out immediately and thereafter on a frequent basis.
83 Trip-testing of oil circuit-breakers provides an operational test and exercises
the mechanism. It can be carried out more frequently than the internal
maintenance, within operational constraints. Annual trip-testing is considered a
suitable frequency by many users and, if combined with tripping via the protection
scheme, also confirms that satisfactory (or otherwise) operation of the complete
tripping system will occur under fault conditions.
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84 Periodic testing of the protection relay scheme is a separate consideration,

which may or may not be undertaken at the same time as maintenance of the
switchgear. Further guidance is provided in the Protection section (paragraphs
153-156).
85 Carrying out intrusive maintenance on oil switchgear introduces risks:
(a) errors can be made in the maintenance procedure, leaving the equipment at
greater risk of failure than if the maintenance had not been carried out;
(b) switching is required in order to release the equipment for maintenance - the
risk of a failure is greatest during a switching operation.
86 So carrying out maintenance too frequently can increase risk and optimising the
maintenance schedule is needed to minimise the overall risk. A suitable method to
establish the correct maintenance interval involves laboratory analysis of oil samples
taken during normal maintenance combined with a thorough inspection by experts
to establish the extent of degradation that has occurred during the maintenance
interval. This can be done on the total population or by sampling. The validity of the
maintenance interval can therefore be established, ie if the degradation is negligible
then the maintenance period can be increased and vice versa if the degradation is
significant. By repeating the procedure at the subsequent maintenance, after the
revised interval, the optimum interval can be derived.
Oil circuit-breakers subject to special duty

87 Oil circuit-breakers that regularly interrupt large load currents, eg those controlling
arc furnaces or frequently operated motors, will require more frequent maintenance
attention than circuit-breakers on normal distribution duty.
88 The level of attention will depend on the nature of the duty being performed in
relation to the rated capability (electrical and mechanical) of the circuit-breakers.
Particular focus will need to be put on monitoring the rate of contact/arc control
device deterioration, oil carbonisation and mechanism wear. In general, the
manufacturers guidance should be sought and implemented.
Insulating oil
89 The reliable performance of oil-filled switchgear depends on the maintenance
of certain basic characteristics of the mineral insulating oil. It is essential that any
new, reclaimed or reconditioned insulating oil is tested prior to being introduced into
equipment to ensure that it meets the required level of performance.
90 Sampling of oil in service can provide valuable information on the deterioration
of the oil and of the switchgear itself and the materials contained within it.
Laboratories with long experience of testing oil samples can provide assessments
of the state of a users switchgear and of the validity of the maintenance
programme. Guidance on the monitoring and maintenance for mineral insulating
oils in electrical equipment is provided in BS 5730 (see Appendix B Further
reading). This includes values and significance of standardised oil tests and uniform
criteria for the evaluation of test data, along with practical details on:
(a) sampling techniques;
(b) testing procedures and assessment criteria;
(c) handling and storage of oil samples.
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Cleaning and inspection of oil-filled chambers

91 Oil-filled chambers should only be cleaned using appropriate cleaning materials,
eg suitable proprietary wipes or synthetic sponges. It is suspected that several
serious accidents have been caused by the presence of fibres from wipes used
in oil-filled distribution equipment. It is therefore extremely important that any wipe
that is used should not release fibres. Similarly, care is needed when using sponges
to avoid tearing, which can allow small sponge fragments to be introduced into
chambers.
92 There are wide variations in the performance of proprietary wipes on the market
and advice on the appropriate types to use should be obtained from suppliers and
specialist organisations. Using disposable gloves and overalls also minimises the
possibility of any contamination by fibres from clothing. The use of chamois leather
cloths rinsed out in clean insulating oil is not recommended for the cleaning of oilfilled chambers.
93 In the presence of trace contaminants in insulating oil, eg acids, peroxides
and moisture, the plating metals such as zinc and cadmium used in switchgear
can form metal salts and soaps, resulting not only in the degradation of the plating
surfaces but also in the degradation of the oil.
94 In particular circumstances, zinc and tin platings can degrade and form a large
number of small whiskers. For switchgear with tin and/or zinc plated components,
particular care should be taken to check all such components for whiskers
immediately following the removal of the oil. Remove any whiskers with an oilsoaked wipe and then dispose of the wipe.
95 The phosphated coatings of steel components in switchgear are known to
degrade in service, resulting in the presence of loose, phosphorous-rich particles
contaminating the oil and coming to rest on the horizontal surfaces of the tank
and other components including bushings and insulators. Switches that contain
phosphated components should be subject to rigorous cleaning to remove
contamination from insulating surfaces. Coated components should also be
thoroughly cleaned to reduce the rate of recontamination of the oil.
96 Cadmium from the plating of mechanism metalwork can react with oil and
moisture to form a cadmium soap, leading not only to the degradation of the
plating surfaces but also to the degradation of the oil. Cadmium soaps on the
surface of solid insulation may lead to electrical degradation of the solid insulation.
To prevent such a degradation, insulator surfaces should be cleaned with an
appropriate solvent. However, because cadmium and cadmium compounds are
highly toxic substances, they need to be handled correctly. Advice on the general
handling of cadmium can be obtained from the HSE leaflet Working with cadmium:
Are you at risk? (see Appendix B Further reading). For guidance on the dealing
of oil contaminated by cadmium or cadmium sludge during tank cleaning see
paragraphs 100-102 and for advice on disposal see paragraphs 191-194.
97 Any switchgear in which there is evidence that the oil is particularly
contaminated should be subjected to rigorous inspection of all components to
check for signs of corrosion, tracking, delamination or other degradation. Degraded
components should be replaced. Of the insulating materials used in switches,
densified wood laminate and pressboard are most susceptible to degradation in
wet environments. As close examination of these components may not indicate
when they have a high moisture content, insulation resistance measurements are
recommended to establish their fitness for continuing in service. You will need to
seek expert advice to establish a test method and recommended pass levels.
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98 Fungal growth can occur in insulating oil that contains free water. The growth
occurs at the interface between water from below and the carbon compounds from
above. The most common fungal growth identified in insulating oil is Cladosporium
Resinae. While it is rare to find fungal growth in insulating oil, any occurrence
needs to be dealt with because as the fungus grows the oil is degraded, producing
more water and various volatiles and acidic conditions that can cause corrosion of
materials. The production of water and resultant corrosion of materials in contact with
the oil will also reduce the insulating properties of the oil.
99 The spores of Cladosporium Resinae are airborne. They can lay dormant for
periods of time and germinate when adequate moisture becomes available. Growth
of the fungus from germinated spores can occur in a temperature range of -25C to
40C. Biocides can be used to kill the spores and it is important to eradicate them
because if they are not destroyed the fungal growth is likely to reoccur.
Tank cleaning techniques

100 In order to clean the inside of switchgear tanks to a satisfactory level, it is
recommended that once the used oil has been removed, the tanks are sprayed/
vacuumed out to remove dirty oil and any particulate contamination from the tank
base and other surfaces. The tanks should be sprayed down with clean oil under
pressure, ensuring all accessible components are sprayed. This oil should then
be removed using a liquid vacuum cleaner. The procedures should be repeated at
least one further time. Examination of the interior of the tank should be completed
to ensure all the contamination has been removed from the tank.
101 Application of the spraying technique can create an oil mist in the immediate
vicinity of the switchgear so suitable personal protective equipment should be
provided and used to prevent inhalation of the oil mist. Where the residual oil in
the tank is known or is suspected to contain cadmium contamination or cadmium
sludge, there is a health risk to personnel carrying out the cleaning process. The
main risks are from inhalation and ingestion. It is recommended that oil-resistant,
disposable overalls and gloves are used, along with the use of fitted chemical
safety goggles. Respirators that prevent the inhalation of the oil mist need to be
used at all times. Personnel need to be made aware of the hazards of ingestion
and that contact with the mouth is to be avoided, along with the need for good
personal hygiene after handling the substances and before eating.
102 A pump dedicated to oil is preferred, with the clean oil pumped using a
separate pump, which should be used exclusively for this purpose. Two separate
hoses, one for clean oil and one for dirty oil, should also be used to ensure no
contamination of the clean oil occurs.
Post-fault maintenance of oil circuit-breakers

103 It is strongly recommended that all oil-filled circuit-breakers are maintained as
soon as possible after they have either been closed onto a fault or have operated
automatically to disconnect a fault from the system. This maintenance should
essentially consist of:
(a) inspection and cleaning of all insulation within the tank to eliminate carbon,
metal vapour/particle contamination;
(b) restoration of the contacts and arc control devices to an acceptable condition
(including a check on contact alignment by slow-closing the oil circuit-breaker);
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(c) replacement of the insulating oil;

(d) inspection of the tank, tank gaskets and tank internal mechanism for signs of
damage or distortion.
104 Where provision is made in the design for venting, this should be checked
to ensure that it is not obstructed and any seal is intact and functioning. Further
guidance on maintenance can be found in manufacturers manuals and in the
relevant British Standards.
Care and maintenance of non-oil

switchgear
General advice
105 Non-oil switchgear makes use of air, sulphur hexafluoride (SF6) or vacuum
as the interrupting medium, the remainder of the switchgear often being airinsulated. In some designs the vacuum interrupter bottles are housed within
sulphur hexafluoride chambers. The appropriate parts of this section also apply to
contactors.
106 An example of an arrangement of a vacuum circuit-breaker is given in
Appendix C3, a sulphur hexafluoride-insulated vacuum circuit-breaker in Appendix
C8 and an air circuit-breaker in Appendix C7.
107 The sealed envelopes of sulphur hexafluoride and vacuum switchgear improve
the reliability by removing the potential degradation of the interrupting medium to
adverse environments such as dust, moisture etc. This has led to the introduction
of the terms low maintenance or reduced maintenance for such switchgear, but
this does not mean that such equipment is maintenance-free. Failures do occur
and inspection/maintenance procedures are required for such equipment. Two
issues should be noted:
(a) With sulphur hexafluoride switchgear a significant proportion of reported
problems are associated with loss of gas through defective/worn seals.
(b) With vacuum switchgear, X-rays may be generated when the open contact
gap is stressed at high-voltage. There are no harmful emissions at normal
service voltage but if a high-voltage pressure test is carried out with the
switchgear in an open position then X-rays may be generated. Guidance
should be sought from the manufacturer on the maximum voltage that can
be applied to ensure that the maximum level of radiation generated is less than
that permitted for unclassified workers in the Ionising Radiation (Sealed
Sources) Regulations 1969.
108 As with oil switchgear, actions can be taken to minimise the risks of
catastrophic failure, eg:
(a)
(b)
(c)
(d)
inspection;
maintenance;
condition monitoring/assessment;
refurbishment/replacement (more likely to be relevant for air-insulated
switchgear as sulphur hexafluoride and vacuum types are modern designs).
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Inspection
109 A regular substation inspection is recommended, as discussed for the oil-filled
switchgear in paragraphs 65-71. This should cover:
(a) switchgear environment;
(b) signs of abnormal condition;
(c) switchgear general condition (for sulphur hexafluoride equipment the gas
pressure gauge should be checked, a pungent smell indicates gas leakage);
(d) checks on all the plant items in the substation.
Maintenance
110 Detailed guidance on the maintenance of electrical switchgear can be found in
BS 6423: 1983 and BS 6626: 1985 (see Appendix B Further reading).
111 Sulphur hexafluoride and vacuum switchgear is designed to be low
maintenance but that does not mean that maintenance can be ignored.
Maintenance using a time-interval approach, based on manufacturers
recommendations, may be applied to such switchgear. Rigorous application of
such schedules should provide high levels of reliability.
112 Condition-based maintenance is an option where maintenance is dictated by
need as revealed by inspections and condition monitoring techniques or predictive
maintenance methods. As with oil-filled switchgear, this requires careful assessment
of the parameters to be monitored, techniques for acquiring the condition data
and, most importantly, an understanding of the degradation mechanisms affecting
the switchgear and the criteria on which the decisions to take action are based.
Before a user considers moving to a condition-based maintenance approach,
the available options should be carefully assessed, preferably with the assistance
of organisations with experience in this area. The performance of switchgear is
influenced by the electrical and environmental conditions under which it operates
and simply applying techniques and criteria from another industry sector may not
be appropriate.
113 Reliability-centred maintenance (see paragraph 77) can assist in the process
of determining the maintenance policy because it analyses maintenance tasks
in a structured way to determine the maintenance requirements of any item of
equipment in its operating context. It does so by taking account of plant usage
and condition, the causes and consequences of failure, together with the required
performance standards of the organisation.
Maintenance procedures
Sulphur hexafluoride switchgear
114 The maintenance work should essentially include:
(a) inspection of the external condition;
(b) checking of gas pressure;
(c) if topping up of the gas is necessary, then refer to precautions in paragraph
130;
(d) inspection, adjustment and lubrication of mechanisms (including shutters where
appropriate);
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(e) on withdrawable equipment, examination of primary isolating contacts for

damage, burning, corrosion - cleaning and refurbishing (as necessary);
(f) on withdrawable equipment, checking and lubrication of circuit-breaker isolating
mechanism;
(g) checking correct function of position indicators and interlocks;
(h) examining inside of cable termination chambers and other chambers as
appropriate, removal of surface contamination from accessible solid insulation
(where applicable);
(i) examining and checking voltage transformer (as required);
(j) secondary injection testing on circuit-breaker protection system (or, if this is not
(k) examination of secondary contacts, wiring and auxiliary switches.
Vacuum switchgear
(b) measurement of contact wear where a measurement method is available;
(c) a check on the vacuum integrity, eg by a high-voltage pressure test (see
warning on X-rays in paragraph 107);
(d) inspection, adjustment and lubrication of mechanisms (including shutters where
appropriate);
(e) on withdrawable equipment, examination of primary isolating contacts for
damage, burning, corrosion - cleaning and refurbishing (as necessary);
(f) on withdrawable equipment, checking and lubrication of circuit-breaker isolating
mechanism;
(g) checking correct function of position indicators and interlocks;
(h) examining inside of cable termination chambers and other chambers as
appropriate - removal of surface contamination from accessible solid insulation
(where applicable);
(i) examining and checking voltage transformer (as required);
(j) secondary injection testing on circuit-breaker protection system (or, if this is not
(k) examination of secondary contacts, wiring and auxiliary switches.
Air-break switchgear
(b) examination of main/arcing contacts for excessive burning/damage recondition or renew as required, taking account of manufacturers
requirements for different contact construction and materials;
(c) checking/adjusting spring contact force and contact alignment as required;
(d) removal, examination and cleaning of the arc chutes - renew if damaged or
eroded;
(e) inspection, adjustment and lubrication of mechanisms (including shutters where
appropriate);
(f) on withdrawable equipment, examination of primary isolating contacts for
damage, burning, corrosion - cleaning and refurbishing as (necessary);
(g) on withdrawable equipment, checking and lubrication of circuit-breaker isolating
mechanism;
(h) checking correct function of position indicators and interlocks;
(i) examining inside of cable termination chambers and other chambers as
appropriate - removal of surface contamination from accessible solid insulation
(where applicable);
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(j) examining and checking voltage transformer (as required);

(k) secondary injection testing on circuit-breaker protection system (or, if this is not
(l) examination of secondary contacts, wiring and auxiliary switches.
Frequency of maintenance
117 Switchgear should be maintained at a frequency appropriate to the equipment
and its duty. The manufacturer, or others, may be able to give advice on this but
difficulties exist in defining the frequency. These are affected by operating policies,
types of switchgear and the reliability requirements. An industrial user whose
activities depend on the reliability of power supply may institute more frequent
maintenance as a means of guarding against power failures than (say) a distribution
company where the duplication built into the network allowing alternative supplies
means that a higher risk of malfunction may be acceptable.
118 For non-oil circuit-breakers subject to special industrial load duties, the
manufacturers guidance should be sought on the level of maintenance required.
119 Trip-testing of circuit-breakers provides an operational test and exercises the
mechanism. It can be carried out more frequently than the internal maintenance,
within operational constraints. Annual trip-testing is considered a suitable frequency
by many users and, if it is combined with tripping via the protection scheme, it also
confirms whether satisfactory operation of the complete tripping system will occur
under fault conditions.
120 Periodic testing of the protection scheme is a separate consideration which
may or may not be undertaken at the same time as the maintenance of the
switchgear. Further guidance is provided in the Protection section (paragraphs
153-156).
Sulphur hexafluoride gas handling and safety precautions

121 Under normal conditions, the sulphur hexafluoride gas remains inside
the switchgear in a sealed system and any decomposition products formed
during interruptions are neutralised by molecular sieves, as well as by natural
recombination processes. However, sulphur hexafluoride can be released at all
stages of the equipment life cycle and procedures for handling it are required.
In order to advise personnel that a substation contains sulphur hexafluoride
equipment it is advisable to post a notice within the substation that clearly states
this.
122 It remains up to an individual user to determine the extent to which they wish
to handle the gas in sulphur hexafluoride-filled switchgear. This can range from,
at one extreme, a decision to make use of external contractors or manufacturers
to deal with all aspects of managing and operating the switchgear, through to
the other extreme of handling it completely in-house. Companies need to ensure
adequate training of personnel and that the required equipment and facilities are
available to proceed with the policy they adopt. Particular attention will need to be
paid to adopting the correct procedures during maintenance, refilling, condition
testing and end-of-life disposal. Expert advice, training and support on these issues
can be obtained from manufacturers, sulphur hexafluoride gas suppliers, electricity
distribution companies and specialist organisations.
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Release of sulphur hexafluoride

123 Sulphur hexafluoride is a greenhouse gas and, although the global warming
effect is likely to remain small compared to other greenhouse gases for the
foreseeable future, control over its use is essential. The European electricity
industries have agreed a set of actions with the manufacturers of sulphur
hexafluoride-filled electrical equipment to reduce emissions of the gas to
atmosphere and recommend good housekeeping by the electricity utilities in line
with the following aims:
(a) sulphur hexafluoride should not be deliberately released into the atmosphere;
(b) sulphur hexafluoride should be recycled and reused to the maximum possible
extent;
(c) losses of sulphur hexafluoride from electrical equipment should be minimised;
(d) all new sulphur hexafluoride equipment should allow for recycling;
(e) standardising recycling procedures should be formulated.
Hazards
124 Procedures for safe handling of sulphur hexafluoride are available from a
number of authorities (see, for example, IEC Technical Report 1634, EA Engineering
Recommendation G69) and from manufacturers. These also give guidance and
safety recommendations on the handling of sulphur hexafluoride due to leaks
from equipment and from any arc by-products. It is generally accepted that, when
properly managed, sulphur hexafluoride does not represent a greater danger for
the user than the other materials (metals, plastics etc) used in any other type
of switchgear whether it is air-insulated, oil-insulated, solid-insulated or vacuum
switchgear.
125 Sulphur hexafluoride in its pure state is inert, colourless, tasteless, nonflammable and non-toxic. However, like nitrogen, it will not support life and a large
volume in the atmosphere may cause personnel to suffer from lack of oxygen.
Sulphur hexafluoride gas is about five times heavier than air, and thus will tend to
accumulate on lower levels such as cable trenches and tunnels.
126 All switchgear containing sulphur hexafluoride used for both insulating and arc
extinction purposes shall be deemed to be contaminated if it has previously been in
electrical service. By-products are generated by sulphur hexafluoride decomposition
due to the energy released during electrical switchgear operations, such as switching,
internal short circuit, partial discharge etc, and these decomposition products are
acidic and corrosive. Users will need to have procedures to call in appropriate and
trained personnel together with the required equipment (which may include personal
protective equipment) to deal with:
(a) emergency situations release of contaminated sulphur hexafluoride gas;
(b) scheduled maintenance of contaminated sulphur hexafluoride equipment
involving access to the sulphur hexafluoride compartment;
(c) testing sulphur hexafluoride gas and filling procedures;
(d) possible contamination in areas surrounding the switchgear;
(e) storage, transport and disposal of contaminated gas.
127 It should be noted that the presence of small quantities of gaseous
decomposition products is accompanied by clear warning signals in the form of a
pungent and unpleasant odour. Irritation occurs within seconds, well in advance of
any dangers arising from poisoning.
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128 Where there is any work on equipment which involves contact with sulphur
hexafluoride or its decomposition products, then the staff should observe the
following precautions:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
use disposable protective overalls;

maintain a high standard of personal hygiene;
do not eat, drink or smoke;
avoid cleaning nose, eyes or face other than with clean paper tissues;
clean off any decomposition products from the work area, clothing and equipment;
dispose of protective overalls in an approved manner;
wash all exposed parts of the body as soon as possible after leaving the
working area.
Sampling
129 The majority of modern switchgear up to 33 kV uses sealed containment
with the sulphur hexafluoride gas at a small, positive gauge pressure (typically 0-1
bar gauge). This type of equipment is completely assembled, filled with sulphur
hexafluoride and tested in the factory and no further handling of the gas is required
during its expected operating life. However, there may be occasions where
sampling and testing of the gas is required. As indicated above, care must be
taken not to release gas into the atmosphere and also to treat it as contaminated
gas. Guidelines for assessing the quality of the gas are available in BS 5207 and
BS 5209. These also provide guidance on quality of new gas and gas to be used
for topping-up switchgear.
Topping-up
130 It may be necessary to top-up the quantity of sulphur hexafluoride within
switchgear if the pressure is found to be below the optimum pressure for that type
of equipment. It is essential that the additional sulphur hexafluoride used be of a
known and satisfactory quality and tested for quality before it is introduced. Where
recycled gas is to be used then specialist equipment is available.
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Care and maintenance of

ancillary equipment
Test probes
131 A number of serious incidents have occurred involving shortcomings with
portable test probes. As a result, it is essential that these items should be
inspected on a regular basis. Including them in an asset register (see paragraph 39)
will allow a regular inspection instruction to be generated and ensure that this is not
overlooked. Use of, for example, a safety colour-coding procedure to indicate the
current period of use will ensure that probes that are outside that period are not
inadvertently used. The checks and actions carried out should include:
(a) inspection of general condition, damage and deterioration;
(b) inspection for correct and legible identification;
(c) cleaning to remove oil films and loose dirt. It is important that only wipes that
do not release fibres should be used;
(d) inspection of contacts for wear, burning or other signs of abnormal condition
and to ensure they are securely attached;
(e) inspection of bushings for cracks, damage, burning etc;
(f) inspection of any guide pins, interlocking tabs and locking bolts to ensure they
and any other parts are securely attached;
(g) measurement of the insulation resistance using an insulation tester and
comparison against an agreed pass figure;
(h) for those probes that are shown to be in satisfactory condition, mark with the
correct code for the current period of use;
(i) removal of any damaged or defective probes from use and initiation of repair or
replacement.
132 It is strongly recommended that all test probes be stored in clean, dry
containers when not in use.
Earthing equipment
133 The earthing equipment for switchgear can be categorised as:
(a) integral part of the permanent operating mechanism of the switchgear;
(b) extensible a system of probes that are attached to a circuit-breaker truck
which can then be racked into an earth position;
(c) portable a system of probes for insertion into the switchgear spouts and
leads for connection to a suitable earth point.
134 This section is concerned with the care and maintenance of the latter two
types (extensible and portable) since these are separate, removable items unlike
the integral types, which will be dealt with as part of the maintenance regime of the
switchgear itself.
135 Portable and extensible types of earthing equipment are vital pieces of safety
equipment and so it is essential that these should be inspected on a regular basis.
Including them in an asset register (see paragraph 39) will allow a regular inspection
instruction to be generated and ensure that this is not overlooked. Use of, for
example, a safety colour-coding procedure to indicate the current period for use will
ensure that equipment that is outside that period is not inadvertently used.
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136 The checks and actions carried out should include:

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
inspection of general condition, damage and deterioration;

inspection for correct and legible identification;
cleaning as required;
inspection of contacts, connections and leads for wear, burning or other signs
of abnormal condition and to ensure they are securely attached;
inspection of all insulation components for damage;
inspection of any guide pins, interlocking tabs and locking bolts to ensure they
are functional and secure;
for earthing equipment that is shown to be in satisfactory condition, mark with
the correct colour code for the current period of use;
removal of any damaged or defective earthing equipment from use and
initiation of repair or replacement.
Testing
Tests to be undertaken during commissioning
137 The commissioning of new (or refurbished) switchgear requires detailed testing
to confirm the functionality of the switch or circuit-breaker, secondary wiring,
protection, indications etc. This requires a detailed checklist of all relevant items
and is beyond the scope of this document. Commissioning should normally be
carried out by the manufacturer or main contractor installing the switchgear, who
will have the necessary experience and expertise to cover all the necessary actions.
Tests to be undertaken during and following maintenance

138 Before being returned to service, the switchgear should be subjected to an
operational check to ensure correct close and open operations. This should include
checks on any interlocks, indicator lamps, local (and remote if applicable) trip
indications, trip counters etc.
139 Automatic circuit-breakers should be tripped using the protection system
to test the complete tripping circuit. Trip-timing tests are valuable to confirm
satisfactory tripping mechanism performance and as a condition-monitoring tool.
140 Also, by reference to the manufacturers maintenance requirements, carry out
any additional testing relating to specific switchgear types.
Diagnostic testing
141 A number of diagnostic tests, both intrusive and non-intrusive, can be
applied to switchgear throughout its life. Such tests may be undertaken during
commissioning in order to establish a baseline for regular testing,
eg mechanism timing/trip profiles. The baseline measurements may then be used
as a basis for a condition-based maintenance strategy.
142 Later in the asset life cycle, diagnostic testing can be carried out to provide
information on the condition of the asset, eg partial discharge measurements on
solid insulation.
143 Where a particular type of switchgear has a known defect affecting its
electrical integrity, diagnostic techniques such as partial discharge detection can
provide effective screening.
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144 Further information on available diagnostic techniques is provided in the

Condition monitoring section (paragraphs 146-152).
Assessment of aged switchgear
145 The risk of catastrophic failure (particularly in the case of oil switchgear)
increases with age and so a process of assessment is needed in order to decide
on the appropriate action for dealing with aged switchgear in service. Such an
approach should incorporate condition assessment where appropriate. Application
of this process will enable rational decisions to be made on whether to retain,
refurbish or replace each switchboard and allow investment to be directed to best
effect. The decisions are made on the basis of condition and on the potential risk of
leaving individual switchboards in service. The decision-making process follows the
assessment actions displayed in the following flowcharts.
Assessment process overview
Phase 2
Condition assessment
Phase 1
Phase 4
Initial considerations
Review and decision
Phase 3
Information assessment
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Phase 1 Initial considerations
Is closing mechanism dependent manual?
Can switchgear be dead operation only or can

new mechanism be fitted?
Phases
2 and 3
Are OCB contacts plain break?
Can arc control devices be fitted to

OCB?
YES
Is fault level in excess of the switchgear fault

rating?
Can network be reconfigured to reduce fault level

to within rating or can switchgear be uprated?
REPLACE SWITCHGEAR
Notes:
(a) If the switchgear has either a dependent manual operating mechanism or, in
the case of oil circuit-breakers, plain break contacts (ie no arc control system),
then it is strongly recommended that it be scheduled for early replacement (or
upgrading if practicable).
(b) If the calculated fault level at the switchboard exceeds the switchgear fault
rating and there is no possibility of reconfiguring the network to reduce the
fault level, then usually the only viable option will be to replace the switchgear
with modern equipment of an adequate rating.
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Phase 2 Condition assessment procedures
Visual inspection
of switchgear and its environment
+
Sample internal examinations
+
Assessment of condition of insulation by partial
discharge detection/ monitoring (and/or other
appropriate diagnostics)
Notes:
(a) If the switchgear is not to be replaced as a result of the Phase 1
considerations, it will be necessary to carry out condition assessment in order
to establish the suitability of the switchgear for continuing service.
The condition assessment should embrace a mixture of external and internal
examination, together with appropriate diagnostic tests to ascertain the
condition of HV insulation.
(b) Information on diagnostics for assessing insulation condition is provided in the
Conditioning monitoring section (paragraphs 146-152).
Phase 3 Information assessment
Consideration of:
Q Fault and defect history
Q Maintenance records/policy/costs
QCondition of enclosure
QSpares availability
Q Operational and network planning issues
additional capacity requirements
redundant circuits
remote control requirements
presence of other plant
Note:
The above information needs to be acquired from the appropriate sources and
assessed.
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Phase 4 Review and decision
Examine accumulated evidence from the condition

assessment and data assessment
Decide on an appropriate course of action
REPLACE
SWITCHGEAR
Decide on
prioritisation
REFURBISH
SWITCHGEAR
PARTS
Where technically and
economically viable
(eg retrofit CB trucks)
RETAIN
SWITCHGEAR
and REVIEW
MAINTENANCE
Q frequency
Q procedure
Q condition monitoring
Note:
If it is decided to retain the switchgear in service, an estimate of remaining life
should be made and the maintenance regime modified to include regular condition
monitoring.
Condition Monitoring
Available techniques
Partial discharge detection
146 Partial discharge (PD) measurements provide a powerful technique to diagnose
the condition of insulation in high-voltage plant. A number of specialist service
companies are able to undertake PD measurements and provide interpretative
guidance on the significance of specific measurements. The following non-intrusive
techniques are available using portable instruments:
(a) measurement of transient earth voltages (TEVs);
(b) ultrasonic detection;
(c) radio frequency interference (RFI) detection.
147 Some surface discharges are best detected using ultrasonic detection
equipment and in practice a combination of TEV and ultrasonics is generally
used on indoor, metal-clad switchgear. RFI can also be used to detect some
advanced partial discharge activity but the technique is limited in application. Where
necessary, the partial discharge measurements are supplemented with intrusive
tests (PD, loss angle and capacitance) and visual inspection to pinpoint the precise
nature of a problem.
148 On strategically important switchboards, permanent partial discharge
monitoring can be considered based on the TEV principle.
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Thermographic surveys
149 Infra-red techniques use either thermal imaging equipment or non-contact
thermometers. The techniques are useful for detecting overheated conductors,
connections and fuses on open-fronted, low-voltage distribution boards or on
other low-voltage switchgear where live parts can be safely exposed and remotely
scanned. These techniques are not particularly useful for indoor high-voltage,
metal-clad switchboards but can detect overheating bushings and connections on
open terminal switchgear.
Mechanism timing tests
150 Many problems in circuit-breakers are attributable to distortion or damage of
the metal parts or stiction in the mechanism causing failure to open or close, or
slow opening of the circuit-breaker. Detection of a problem in a mechanism may
not be fully dealt with by invasive maintenance and in fact may be more effectively
dealt with by incorporating timing tests into the periodic trip-tests which can be
carried out at the time of, or independently of, maintenance activities. As well as
straightforward timing, the use of trip-profile instruments provides a more detailed
appreciation of the mechanism performance and is potentially a valuable additional
test that can be incorporated into the routine trip-testing procedure. A number of
instruments are available on the market and specialist organisations can provide a
testing and assessment service.
Strategies for application

151 The application of diagnostic techniques, whether non-intrusive or intrusive,
assists users by providing:
(a) confidence in the continuing safety and reliability of the switchgear;
(b) a sound engineering basis for making investment decisions on plant
replacement or refurbishment;
(c) the basis of a cost-reduced maintenance strategy, ie incorporating condition
monitoring.
152 Switchgear that is not to be replaced as a result of a condition assessment
programme, and is found suitable for further service, will require a maintenance
regime modified to include some form of ongoing condition monitoring.
Non-intrusive diagnostic techniques can form a part of that condition-monitoring
programme.
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Protection
Protection relay schemes
153 The protection relays and associated systems should be subjected to regular
inspection and diagnostic testing in addition to routine maintenance actions.
Diagnostic testing will give an indication of the condition and comparison of test
results with records of previous results will provide a guide to possible deterioration
and assist in determining the appropriate testing/maintenance interval. This
procedure is valuable for estimation of trends.
154 Insulation resistance testing should be carried out on the secondary wiring
associated with the protection, including any pilot wires if they form part of the
protection circuitry. This is important since current leakage across the wiring will
affect the characteristics of the protection scheme and may have a detrimental
effect on the operation and discrimination of the protection scheme.
155 The checks and actions carried out for protection relay schemes should
include:
(a) ensuring relay settings are correct;
(b) inspection for condition, damage and deterioration. For an electromechanicaltype relay this should include checks that:
relay movement runs freely;
magnet gaps and induction disc are clean;
contacts are not burnt or pitted (refurbish as necessary);
induction disc resetting time (electromechanical IDMT relays);
flag mechanisms and reset knobs operate correctly;
front cover glass and seals are satisfactory;
current transformer shorting contacts operate satisfactorily;
(c) secondary injection tests to check operating characteristics. These tests will be
dependent on the protection type (instantaneous and IDMT overcurrent/earth
fault, directional, auto-reclose, unit, distance, motor protection etc) and whether
time-limit fuses are used. Guidance on the test procedure can be obtained from
manufacturers or specialist testing companies;
(d) checking the correct operation of load ammeters and any other instruments;
(e) insulation resistance testing.
(f) trip-testing of the circuit-breaker from the protection;
(g) inspection of the associated current and voltage transformers where
appropriate.
Fuse protection
156 For switchgear where the protection is dependent on fuse operation (eg switch
fuses and fuse switches) then the operation tests involve carrying out fuse trip-testing
(a test-trip fuse can be used if available) to ensure that:
(a) single fuse operation causes all other phases to operate;
(b) the manual ON/OFF trip mechanism operates correctly.
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Batteries and chargers
157 Batteries for circuit-breaker tripping and closing supplies play a vital role in
the overall performance of the switchgear. The batteries and associated chargers
need an appropriate maintenance regime in order to ensure consistent and reliable
performance.
158 The battery/charger installation should be regularly inspected, tested and
maintained. The level of maintenance attention will depend on the type of battery
and type of charger system in use. The battery manufacturers operation and
maintenance instructions should be followed, and in particular, the recommended
charging rates should be adhered to.
159 All work on substation batteries needs to be carried out in accordance with the
safety rules applicable to the work and only insulating tools complying with BS EN
60900 (see Appendix B Further reading) and other suitable equipment are to be
used.
160 Care needs to be taken to ensure that removal of connections does not
inadvertently immobilise the switchgear or associated equipment.
161 Smoking or the use of naked flames should not be allowed in the proximity
of battery installations and the production of sparks should be avoided due to
inadvertent short-circuiting of cells.
162 When batteries are replaced it is important that the existing battery charger is
compatible with the new batteries and old batteries are disposed of, observing the
relevant environmental legislation.
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Selection of new, replacement or

refurbished switchgear
General advice
163 A completely new switchboard installation will utilise the latest designs on
offer from manufacturers. However, where a decision has to be taken to replace
switchgear in an existing installation, then a number of options are available:
(a)
(b)
(c)
(d)
replace the switchboard in its entirety;

replace the individual switchgear units (moving and fixed portion);
refurbish the switchboards or individual switchgear units;
retrofit the switchgear (this usually applies to circuit-breakers).
164 A major factor in such a decision is to obtain some technical confidence that
the high-voltage insulation components of the busbar system, current transformer
chambers, cables and terminations etc have adequate remaining life to justify any
proposed expenditure on partial replacement, refurbishment or retrofitting. For this
reason it is essential that an overall assessment of the switchgear is carried out
before evaluating the economics of refurbishment/retrofit against replacement. This
should include condition assessment of the high-voltage insulation using partial
discharge measurement techniques. Included in this process is the evaluation
of available test data and relevant standards. Where circuit-breakers are under
consideration, it is also important to consider:
(a)
(b)
(c)
(d)
the condition of the secondary wiring, protection and control equipment;

interlocking and earthing arrangements in relation to current safety standards;
short-circuit ratings;
venting arrangement (where appropriate).
165 The availability of spares plays a role in the decision process. Consideration
should be given to the availability of both strategic items (eg bushings, current
transformer chambers, cable boxes, mechanisms) and routine maintenance
items (eg arcing contacts, turbulator inserts, gaskets, tripping and closing coils).
Confirmation should be sought as to whether spares are available from the original
equipment manufacturer (OEM), or the OEMs successor companies, or from small
specialist engineering companies.
Ratings
166 The load rating and the short-circuit rating of any new/refurbished/retrofit
switchgear should be assessed relative to that of any of the fixed portion and
ancillary equipment such as the current transformers that are to be retained. It
is not unknown for users to overlook the fact that where there is a mismatch
between the replaced/refurbished equipment and the existing equipment then the
lowest load and short-circuit rating apply. Consequently, they may install uprated
switchgear that cannot be utilised to its full rating.
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Replacement installations
167 Where a complete new switchboard is to be installed, the opportunity exists
to consider whether direct replacement is necessary or whether the switchboard
arrangement can be simplified. You also need to take account of the possible
additional capacity benefits and the reduced maintenance costs associated with the
new switchgear. Also, less space will generally be required and the opportunity given
to modernise the protection and control schemes.
168 Where only individual switchgear panels are to be replaced, then the decision is
one of a like-for-like replacement, if it is still available, or of a modern equivalent (see
also circuit-breaker retrofit option described in paragraphs 172-174).
169 It should be noted that old paper/lead cables can be internally damaged by
significant disturbance and appropriate measures need to be taken to avoid this.
Refurbished/retrofitted switchgear
170 Users should only embark on the refurbishment and/or retrofit route after an
overall assessment of those parts of the switchgear to be retained has been carried
out. This is necessary to confirm that the retained parts have adequate rating and
sufficient remaining life to justify the expenditure on refurbishment/retrofitting. The
options available are refurbishment of switchgear or retrofitting of circuit-breakers.
Refurbishment of switchgear
171 This can be viewed as a major overhaul of the switchgear with replacement
of parts deemed to be time-expired, eg operating mechanisms, insulation
components etc.
Retrofit circuit-breakers for withdrawable switchgear
172 Retrofitting involves updating the existing moving portions of switchgear,
generally to incorporate vacuum or sulphur hexafluoride technology, for use with
the existing fixed portions. Two options can be considered:
(a) replacing the complete circuit-breaker truck; or
(b) modifying the existing truck to incorporate a vacuum or sulphur hexafluoride
circuit-breaker.
173 Retrofit systems can be obtained either from switchgear manufacturers or
specialist retrofit suppliers. When selecting a system, particular attention should be
paid to the mechanical compatibility between the fixed portion and the new moving
portion. Problems can be experienced due to mechanical mismatch between the
mating portions, shutter actuation, racking mechanisms and physical clearances.
These are better addressed at the planning stage rather than attempting to cure
them at the installation stage. Such problems can be minimised by close liaison
between the user and supplier at all stages of a retrofit operation.
174 It is good practice to carry out a partial discharge survey of the switchboard,
prior to installation of the retrofit units, to establish the integrity of the existing
equipment and repeat the survey after installation to ensure that problems have not
been exacerbated or introduced.
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Second-hand equipment
175 It is possible to purchase second-hand switchgear from companies
specialising in the recovery of redundant switchgear and in its refurbishment for
re-sale. If second-hand switchgear is being considered, it is important to only deal
with reputable and experienced organisations. Such organisations are required
to provide documentation on the use and maintenance of the equipment. This
would include information originating from the OEM. An audit of the contract
by an independent consultant can be a worthwhile safeguard against purchase
of equipment that might not be fit for purpose. The companies supplying the
refurbished equipment though should ensure all relevant items are dealt with during
overhaul, upgrades, modifications etc.
Measures to limit fires
176 Failure of switchgear can lead to fires and where oil-filled equipment is involved
the incident can be a major one. A serious incident not only poses potential fire and
smoke risks to people in the vicinity and to the building fabric but may also affect
other plant, thus escalating the primary event. There are a number of techniques
that can be used singularly or in combination to mitigate the effects of a fire and
limit smoke spread.
Compartmentation
177 Substation plant items can be separated by fire-resisting barriers to limit
the extent of any fire to the item of fire origin. If automatic extinction or control is
required (see paragraphs 178-180), then compartmentation is useful. However,
there may be contradictory requirements between fire safety and explosion safety,
for example where venting may be required to safeguard against explosion.
Compartmentation needs to be carefully designed so that it can contain a fire but
not inhibit any venting required for explosion control.
Control and extinction

178 Fire-extinguishing systems use extinguishing mediums such as halon and
carbon dioxide (CO2). Halon is not a favoured medium due to environmental
considerations but its use may be necessary in areas where fire hazards are
particularly severe and could affect adjacent plant.
179 Such systems require the flooding of fire compartments and measures should
be put in place to ensure that the system can be made non-automatic before entry
to cater for occasions when personnel need to work in the area (see paragraphs
183-185).
180 A review of the use and provision of portable fire-extinguishers and procedures
for checking these and any permanent systems should also be carried out. Where
problems are identified either in the design, operation or during inspections, then
corrective actions such as replacement, recharging and relocation etc should be
taken.
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Prevention
181 The most appropriate control measure is that of prevention. The following
strategies can be considered:
(a) good management of the plant items, eg careful control of workmanship,
as there is a greater likelihood of an incident occurring after replacement or
maintenance of equipment;
(b) careful monitoring of any degradation of oil and dielectric insulation;
(c) reduction of possible ignition sources;
(d) good housekeeping.
Detection
182 The use of an appropriate automatic fire detection system could provide the
electrical plant room or area with early fire detection and alarm features which
could also be linked with a control/extinction system to provide fast response fire
suppression or control.
Safety issues
183 Where automatic fire protection systems are installed there are risks to people
in the protected area when the system operates. These include:
(a) asphyxiation by the gases or chemical extinguishants used;
(b) poisoning if extinguishants are toxic;
(c) physical injury (falling, striking objects etc) due to poor visibility after release of
the gases or chemical extinguishants;
(d) effect of low temperature due to release of the gases or chemical
extinguishants.
184 Precautions should therefore be taken if people are to enter an area fitted with
automatic fire protection equipment. These include:
(a) the automatic control to be rendered inoperative before entry;
(b) caution notices indicating that the control is on non-automatic to be fitted to
the automatic/non-automatic selector;
(c) precautions taken to render the automatic control inoperative to be noted in
any safety documents issued for work in the protected area;
(d) instructions issued to staff to ensure that the system is restored to automatic
control as soon as all staff have withdrawn from the area.
185 Notices requiring the above actions should be prominently displayed at the
point(s) of access to the area.
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Training
General advice
186 It is the duty of all users of switchgear to provide necessary training in order
that staff involved in the operation and maintenance of switchgear are able to
carry out their duties in safety and without risk to health. Many organisations
offer a full range of training courses, from general appreciation of site access and
responsibilities through to detailed courses on operations, safety, maintenance
practice etc. Such organisations include:
(a)
(b)
(c)
(d)
electricity distribution companies;

training companies;
switchgear manufacturers;
technical services companies.
187 The use of a set of safety rules and a system of safety documents (see
paragraph 188 for definitions) that clearly and unambiguously state what actions
are required to ensure safe working is essential, particularly at high voltage. To
ensure that the different levels of activity associated with switchgear are performed
competently and the safety rules are strictly adhered to, it is also important to
define different categories of staff. This means you can clearly define the duties that
are expected of them and, just as important, those they are not authorised to carry
out. Typical categories are as follows (training courses can be prepared to meet the
requirements of these categories):
(a) competent person a person recognised as having sufficient technical
knowledge and/or experience to enable them to avoid danger when carrying
out their duties and who may be nominated to receive and clear specified
safety documents;
(b) authorised person a competent person who has been appointed in writing
to carry out specified duties, including the issue and cancellation of safety
documents, eg a permit-to-work or sanction for test.
Operational safety documents

188 The activities needed to operate, inspect, repair, maintain and test the
switchgear will be designated to the appropriate category of person. In all cases,
knowledge of the safety rules and application of the safety documents will be
required, whether this be general understanding or detailed knowledge, plus an
appreciation of the issues raised in this book. The implementation of a safety
documents scheme is fundamental to safety in the use, care and maintenance of
plant. The correct use of the following documents is essential. The naming of the
documents varies between organisations - here are some suggested ones.
(a) Limitation of access defines the limit within which work or testing (on LV
switchgear and systems) may be carried out and specifies necessary
precautions.
(b) Permit-to-work specifies the equipment to be worked on, the work to be
carried out and the actions taken to achieve conditions which safeguard people
working on the equipment from the dangers that are inherent in the system.
(c) Sanction for test specifies the HV equipment to be tested, making known the
conditions under which the testing is to be carried out and confirming actions
taken to achieve conditions which safeguard persons testing the equipment
from the dangers that are inherent in the system.
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189 Operational safety documents are not intended (and should not be used) for
work control purposes.
Inspection and maintenance

190 Personnel engaged on the inspection and maintenance of switchgear will need
to be made familiar with the procedures, safety rules and safety documents under
which they work and their responsibilities to ensure safety and safe working. They
will also need training in the technical aspects of their work.
Disposal issues
191 Anyone who produces, treats, keeps, stores, transports or disposes of waste
is subject to a duty of care under section 34 of the Environmental Protection Act
1990. This makes holders of waste responsible for its fate even after it has left their
hands.
Insulating oil
192 Much of the used oil from switchgear is returned to oil companies and is
subject to a process to generate reclaimed oil (which is sold back to the users
for reuse). Within the reclaiming and refining processes, the oil companies have
their own quality assurance/quality control procedures, which should ensure that
the quality and performance of the reclaimed oil being supplied back to users is
satisfactory. It is standard practice within the oil companies to check the quality of
batches of oil returned for reclaiming and reject those that are severely degraded.
Users with known batches of badly degraded oil should keep it as separate waste
oil for disposal by the oil companies in an appropriate manner.
193 Switchgear oil may contain polychlorinated biphenyls (PCBs), so the
procedures for handling used oil should take account of the approved handling
procedures for PCB-contaminated materials or substances as laid down by:
(a) EU Directive 96/59/EC The Disposal of Polychlorinated Biphenyls and
Polychlorinated Triphenyls;
(b) Statutory Instrument SI 2000 No 1034 The Disposal of Polychlorinated Biphenyls
and Other Dangerous Substances Regulations (England and Wales) May 2000.
194 As discussed in paragraphs 91-99, used switchgear oil may contain cadmium
or cadmium sludge. Where this situation arises, the oil, cadmium sludge and all
material containing it needs to be treated as special waste and the disposal
needs to be carried out as laid down by The Special Waste Regulations 1996. This
includes all oil containing the cadmium and any new oil or solvents used to clean
and rinse the components within the tank. Any wipes, gloves or clothing that have
come into contact with the cadmium should be collected and sealed in boxes. All
of this should then be appropriately labelled as special waste.
Capacitors
195 Some capacitors contain PCBs and therefore the procedures for disposal of
capacitors should take account of approved handling procedures for PCBcontaminated materials or substances see the documents referred to in
paragraph 193.
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Sulphur hexafluoride switchgear

196 As stated previously, there is a need to reduce emissions into the atmosphere
and so procedures need to be in place to deal with the reclamation or disposal
of sulphur hexafluoride gas removed from switchgear and for the disposal of
switchgear containing sulphur hexafluoride. Advice on procedures can be obtained
from the switchgear manufacturers and from specialist disposal companies.
Guidance on the safe handling and final disposal is available from:
(a) CIGRE Technical Brochure No 117, 1997 SF6 recycling guide. Re-use of SF6
gas in electrical power equipment and final disposal;
(b) IEC Technical Report 1634, 1995 High-voltage switchgear and
controlgear use and handling of sulphur hexafluoride in high-voltage
switchgear and controlgear.
197 Transportation by road of sulphur hexafluoride in gas bottles or equipment
containing it is subject to national and local regulations. Information can be
obtained from the European Agreement Concerning the International Carriage of
Dangerous Goods by Road (ADR) and protocol of significance.
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Appendix A: Technical definitions
Low voltage
Normally exceeding 50 V ac or 120 Vdc but not exceeding 1000 V ac or 1500 V dc
between conductors, or 600 V ac or 900 V dc between conductors and earth.
High voltage
Normally exceeding 1000 V ac or 1500 V dc between conductors, or 600 V ac or
900 V dc between conductors and earth.
Medium voltage
Some companies and persons use the term medium voltage to describe
distribution voltages in range 3.3 kV to 72.5 kV to distinguish these from the higher
values of voltage associated with transmission systems. There is no International
Electrotechnical Vocabulary (IEV) meaning which specifies values; all that is stated
is that the upper value lies between 30 kV and 100 kV. The term has not been used
in the UK to prevent confusion with the widely understood use of the term for 415
V three-phase systems.
Switchgear
A combination of one or more switching devices together with associated control,
measuring, signal, protective, regulating equipment etc completely assembled
under the responsibility of the manufacturer with all the internal electrical and
mechanical interconnections and structural parts.
Switching devices
It is possible to separate switching devices into the following groups and to define
the type of switching device. It should be noted that they are all electromechanical
devices.
Isolator
A switching device which is used to open (or close) a circuit either when negligible
current is interrupted (or established) or when no significant change in the voltage
across the terminals of each pole or phase of the isolator will result from the
operation.
Switch
A switching device suitable for making or closing a circuit under normal and
abnormal conditions, such as those of short-circuit, and capable of breaking or
opening a circuit under normal conditions.
Circuit-breaker
A switching device capable of making and breaking, or closing and opening, a
circuit under normal conditions and under abnormal conditions such as those of
short-circuit.
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Switch fuse
A switching device that is an integral assembly of switch and fuses in which a fuse
is connected in series with the switch.
Fuse switch
A switching device in which a fuse link or fuse carrier constitutes the moving
contact.
Operating duties
The operating duties of the above switching devices may be summarised as
follows:
Q An isolator has no rated making or breaking capability, ie these devices can
only be used for OFF-LOAD or DEAD switching.
Q A switch is a FAULT MAKE/LOAD BREAK device.
Q A circuit-breaker is a FAULT MAKE/FAULT BREAK device.
Operating mechanisms
The types of operating mechanisms used for these switching devices are defined
as follows:
Q Dependent manual operation (of a mechanical switching device) (IEV
Definition 441-16-13)
An operation solely by means of directly applied manual energy such that the
speed and force of the operation are dependent upon the action of the
operator.
Q Independent manual operation (of a mechanical switching device) (IEV
A stored energy operation where the energy originates from manual power,
stored and released in one continuous operation, such that the speed and
force of the operation are independent of the action of the operator.
Q Dependent power operation (of a mechanical switching device) (IEV
An operation by means of energy other than manual, where the completion of
the operation is dependent upon the continuity of the power supply
(to solenoids, electric or pneumatic motors etc).
Q Independent power operation (of a mechanical switching device) (IEV
A stored energy operation where the stored energy originates from an external
power source and is released in one continuous operation, such that the speed
and force of the operation are independent of the action of the operator.
Q Stored energy operation (of a mechanical switching device) (IEV Definition
441-16-15)
An operation by means of energy stored in the mechanism itself prior to the
completion of the operation and sufficient to complete it under predetermined
conditions. This kind of operation may be subdivided according to:
(a) the manner of storing the energy (spring, weight etc);
(b) the origin of the energy (manual, electric etc);
(c) the manner of releasing the energy (manual, electric etc).
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Appendix B: Further reading
General advice (including HSE publications)

The Health and Safety at Work etc Act 1974 The Stationery Office 1974
ISBN 0 10 543774 3
Management of health and safety at work. Management of Health and Safety at
Work Regulations 1999. Approved Code of Practice and guidance L21 (Second
edition) HSE Books 2000 ISBN 0 7176 2488 9
Memorandum of guidance on the Electricity at Work Regulations 1989
HSE Books 1989 ISBN 0 7176 1602 9
Occupational exposure limits: Containing the list of maximum exposure limits
and occupational exposure standards for use with the Control of Substances
Hazardous to Health Regulations 1999 Environmental Hygiene Guidance Note
EH40 (revised annually) HSE Books 2002 ISBN 0 7176 2083 2
Working with cadmium: Are you at risk? Leaflet MSA7 HSE Books 1995 (also
available on the HSE website at http://www.hse.gov.uk/pubns/msa7.htm)
Switchgear general
CH Flurscheim Power circuit-breaker theory and design Peter Peregrinus Ltd 1985
ISBN 0906048702
R T Lythall The J and P Switchgear Book: An outline of modern switchgear practice
for the non-specialist user 1972 edition Newnes/Butterworth-Heinemann
ISBN 0408000694
BS 3078: 1959 Isolators (including selectors) for alternating current systems
BS 4752: 1977: Part 1 Switchgear and control gear for voltage up to and including
1000 V ac and 1200 V in dc circuit-breakers
BS 5311: 1976: Parts 1 to 5 AC circuit-breakers of rated voltage above 1 kV
BS 5311: 1996 High-voltage alternating-current circuit-breakers
BS 5463: 1977 AC switches of rated voltage above 1 kV
BS 60947: Specification for low-voltage switchgear and controlgear general
requirements and circuit-breakers
BS 6423: 1983 Code of Practice for main-tenance of electrical switchgear and
controlgear for voltages up to and including 1 kV
BS 6626: 1985 Code of Practice for maintenance of electrical switchgear and
controlgear for voltages above 1 kV and up to and including 36 kV
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British Standards relating to oil switchgear

BS 116: 1937 Part 1 Oil circuit-breakers, oil switches and oil isolating-switches for
alternating current circuits (three-phase oil circuit-breakers with breaking capacity
ratings between 25 and 500 MVA)
BS 116: 1952 Oil circuit-breakers for ac systems
BS 936: 1940 Oil circuit-breakers for medium voltage ac systems (up to 660 V)
BS 936: 1960 Oil circuit-breakers for medium voltage ac systems (up to 660 V)
BS 2631: 1955 Oil switches for alternating current systems
BS 5730: 1979 Monitoring and maintenance guide for mineral insulating oil
electrical equipment (under review based on IEC 60422)
Handling and use of sulphur hexafluoride

BS 5207: 1975 Specification for sulphur hexafluoride for electrical equipment
BS 5209: 1975 Code of Practice for the testing of sulphur hexafluoride taken from
electrical equipment
SF6 recycling guide: Re-use of SF6 gas in electrical power equipment and final
disposal CIGRE Technical Brochure No 117 1997
Guidance on the safety aspects of work on sulphur hexafluoride-filled distribution
equipment up to 145 kV EA Engineering Recommendation G69 1988
IEC 376: 1971 Specification and acceptance of new sulphur hexafluoride
IEC 480: 1974 Guide to checking of sulphur hexafluoride (SF6) taken from electrical
equipment
IEC 694: 1995 High-voltage switchgear and controlgear. Use and handling of
sulphur hexafluoride (SF6) in high-voltage switchgear and controlgear
High-voltage switchgear and controlgear use and handling of sulphur hexafluoride
in high-voltage switchgear and controlgear IEC Technical Report 1634 (First edition)
1995. Reference No CEI/IEC 1634:1995.
LV installations
BS 7671: 2001 Requirement for Electrical Installations (IEE Wiring Regulations)
Seventeenth edition
Disposal of hazardous materials

EU Directive 96/59/EC The Disposal of Polychlorinated Biphenyls and
Polychlorinated Triphenyls European Commission
The Disposal of Polychlorinated Biphenyls and Other Dangerous Substances
Regulations (England and Wales) SI 2000/1034 The Stationery Office May 2000
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The Special Waste Regulations 1996 The Stationery Office

European Agreement Concerning the International Carriage of Dangerous Goods
by Road (ADR) and protocol of significance The Stationery Office
RCM background
Smith A M Reliability-centred maintenance Wiley New York 1992
Moubray J Reliability-centred maintenance Butterworth-Heinemann Oxford 1991
Generator protection settings

Recommendations for the connection of embedded generating plant to the
public electricity suppliers distribution systems Electricity Association Engineering
Recommendation G59/1 1991
Recommendations for the connection of embedded generating plant to public
electricity suppliers distribution systems above 20 kV or with outputs over 5 MW
Electricity Association Engineering Recommendation G75 1996
Insulating tools
BS EN 60900 1994 Hand tools for live working up to 1000 V ac and 1500 V dc
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Appendix C: Examples of
switchgear configurations
Appendix C1: Typical arrangement of a horizontal isolation duplicate

busbar 11 kV oil circuit-breaker
MAIN ISOLATING
CONTACTS
OPERATING
MECHANISM
BUSBARS
CURRENT
TRANSFORMERS
CIRCUIT-BREAKER
OIL TANKER
CABLE BOX
VOLTAGE
TRANSFORMER
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Appendix C2: Typical arrangement of a vertical isolation 11 kV oil

circuit-breaker panel (single busbar with feeder earthing via circuitbreaker transfer)
OIL-FILLED VOLTAGE
TRANSFORMER
CURRENT
TRANSFORMERS
EARTHING
CONTACTS
MAIN ISOLATING
CONTACTS
CIRCUIT-BREAKER
TANK
CIRCUIT-BREAKER
CARRIAGE
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Appendix C3: Typical arrangement of a single selector fixed pattern

11 kV vacuum circuit-breaker
VOLTAGE
TRANSFORMER
RELAY PANEL
TEST ACCESS
AND COVER
CABLE BOX
VACUUM
INTERRUPTERS
CLOSING AND
SELECTOR
MECHANISMS
Appendix C4: Typical arrangement of an 11 kV oil switch
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Appendix C4: Typical arrangement of an 11 kV oil switch
COMPOUND FILLED
BUSBAR CHAMBER
TEST ACCESS
OPERATING
HANDLE
CABLE BOX
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Appendix C5: Typical arrangement of an 11 kV oil fuse switch
TEE OFF
BUSHING
HV FUSE
MOVING
CONTACT
EARTH
SWITCH
FIXED
CONTACT
CABLE
BOX
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Appendix C6: Typical arrangement of an 11 kV oil-filled common

tank ring main unit (incorporating two ring switches and one fuse
switch)
RING SWITCH
TEST ACCESS
COVERS
FUSE ACCESS
COVER
HV FUSES
RING SWITCH
MAIN CONTACTS
RING SWITCH
BLADES
SWITCH
BLADES
RING SWITCH
EARTH CONTACTS
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Appendix C7: Typical arrangement of a 415 V air circuit-breaker
CONTACTS AND
ARC CHUTES
ISOLATOR
CLOSED POSITION
REMOVABLE
HANDLE
CIRCUIT-BREAKER
CLOSED POSITION
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Appendix C8: Typical arrangement of a 33 kV fixed-pattern vacuum

circuit-breaker with sulphur hexafluoride (SF6) gas insulation
CURRENT
TRANSFORMERS
CIRCUIT-BREAKER
MECHANISM
VACUUM
INTERRUPTERS
VOLTAGE
TRANSFORMER
SELECTOR
MECHANISM
RESIN
ENCAPSULATED
BUSBARS
SELECTOR SWITCH
IN SF6 GAS
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Appendix D: Other sources of

information
British Electrotechnical and Allied Manufacturers Association (BEAMA)
Westminster Tower
3 Albert Embankment
London
SE1 7SL
Tel: 020 7793 3000
The Institution of Electrical Engineers (IEE)
Savoy Place
London
WC2R 0BL
Tel: 020 7240 1871
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Further information
HSE priced and free publications can be viewed online or ordered from
www.hse.gov.uk or contact HSE Books, PO Box 1999, Sudbury, Suffolk
CO10 2WA Tel: 01787 881165 Fax: 01787 313995. HSE priced publications
are also available from bookshops.
For information about health and safety ring HSEs Infoline Tel: 0845 345 0055
Fax: 0845 408 9566 Textphone: 0845 408 9577 e-mail: hse.infoline@natbrit.com or
write to HSE Information Services, Caerphilly Business Park, Caerphilly CF83 3GG.
British Standards can be obtained in PDF or hard copy formats from BSI:
http://shop.bsigroup.com or by contacting BSI Customer Services for hard
copies only Tel: 020 8996 9001 e-mail: cservices@bsigroup.com.
The Stationery Office publications are available from The Stationery Office, PO
Box 29, Norwich NR3 1GN Tel: 0870 600 5522 Fax: 0870 600 5533 e-mail:
customer.services@tso.co.uk Website: www.tso.co.uk (They are also available from
bookshops.) Statutory Instruments can be viewed free of charge at
www.opsi.gov.uk.
Published by HSE
02/10
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Health and Safety

Keeping electrical switchgear

Health and Safety

Crown copyright 2002

a retrieval system, or transmitted in any form or by any means (electronic,

mechanical, photocopying, recording or otherwise) without the prior written

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guidance as illustrating good practice.

Health and Safety

Equipment and its location 7

Potential problems with switchgear 8

Dependent manual operating mechanisms 9

Fault levels and ratings 13

Effect of on-site generation and other large rotating machines 14

Precautions for reducing the risk of switchgear failure and injury 14

Dependent manually operated (DMO) switchgear 15

Care and maintenance of oil switchgear 17

Signs of abnormal condition 18

Switchgear general condition 18

Time-based preventive maintenance 19

Reliability-centred maintenance (RCM) 19

Oil circuit-breakers subject to special duty 21

Cleaning and inspection of oil-filled chambers 22

Tank cleaning techniques 23

Post-fault maintenance of oil circuit-breakers 23

Keeping electrical switchgear safe

Health and Safety

Care and maintenance of non-oil switchgear 24

Sulphur hexafluoride switchgear 25

Sulphur hexafluoride gas handling and safety precautions 27

Release of sulphur hexafluoride 28

Care and maintenance of ancillary equipment 30

Tests to be undertaken during commissioning 31

Tests to be undertaken during and following maintenance 31

Assessment of aged switchgear 32

Assessment process overview 32

Phase 1 Initial considerations 33

Phase 2 Condition assessment procedures 34

Phase 3 Information assessment 34

Phase 4 Review and decision 35

Partial discharge detection 35

Mechanism timing tests 36

Strategies for application 36

Protection relay schemes 37

Batteries and chargers 38

Selection of new, replacement or refurbished switchgear 39

Retrofit circuit-breakers for withdrawable switchgear 40

Keeping electrical switchgear safe

Health and Safety

Measures to limit fires 41

Control and extinction 41

Operational safety documents 43

Inspection and maintenance 44

Sulphur hexafluoride switchgear 45

C Examples of switchgear configurations 51

D Other sources of information 59

Keeping electrical switchgear safe

Health and Safety

1 This book is aimed primarily at owners and operators of electrical switchgear

Keeping electrical switchgear safe